WO2008027805A1 - Capot de camion en matériau hybride léger - Google Patents

Capot de camion en matériau hybride léger Download PDF

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Publication number
WO2008027805A1
WO2008027805A1 PCT/US2007/076765 US2007076765W WO2008027805A1 WO 2008027805 A1 WO2008027805 A1 WO 2008027805A1 US 2007076765 W US2007076765 W US 2007076765W WO 2008027805 A1 WO2008027805 A1 WO 2008027805A1
Authority
WO
WIPO (PCT)
Prior art keywords
hood
skin
metal
truck
reinforcement
Prior art date
Application number
PCT/US2007/076765
Other languages
English (en)
Inventor
Dinesh C. Seksaria
Russell S. Long
Original Assignee
Alcoa Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Alcoa Inc. filed Critical Alcoa Inc.
Publication of WO2008027805A1 publication Critical patent/WO2008027805A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/08—Front or rear portions
    • B62D25/10—Bonnets or lids, e.g. for trucks, tractors, busses, work vehicles
    • B62D25/105—Bonnets or lids, e.g. for trucks, tractors, busses, work vehicles for motor cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B62D29/005—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material preformed metal and synthetic material elements being joined together, e.g. by adhesives

Definitions

  • the present invention relates to the lightweight truck hoods. More specifically, the invention provides a truck hood made from aluminum and having reinforcement members that may be made from polymers and aluminum.
  • hoods are made from either sheet metal or polymer fiber composites.
  • Hoods made from sheet metal typically include several components added to the hood panel itself to provide structural support and durability. These components increase the weight and cost of manufacture of the hood.
  • Fiberglass reinforced plastic (composite) hoods require slow, labor intensive manufacturing processes More specifically, manufacturing of fiberglass reinforced plastic hoods typically includes the steps of providing a wooden mold, spraying a fiberglass media into the mold, and then applying a polymer resin. Each of these steps are manual labor intensive steps resulting in high production time for a singular hood Such composite hoods must often be thicker, typically on the order of 6.0 mm or greater, to provide the required strength.
  • FIGs 1 -5 illustrate a typical reinforcement structure presently used with fiberglass reinforced plastic truck hoods.
  • the reinforcement structure 10 is formed of fiberglass reinforced plastic and includes a front reinforcement 12 having a generally rectangular configuration, defined by the top 14, bottom 16, and sides 18, 20.
  • the right side 18 and left side 20 each define a headlight reinforcement portion 22, 24, respectively, extending outward therefrom.
  • the remainder of the headlight reinforcement is a separate piece, with the left side headlight reinforcement 26 illustrated in Figure 3, and the right side headlight reinforcement being a mirror image of the left side reinforcement 26.
  • a right side reinforcement 28 and left side reinforcement 30 extend rearward from the front reinforcement 12.
  • the right side reinforcement 28 is a mirror image of the left side reinforcement 30.
  • Each of the left side reinforcement 30 and right side reinforcement 28 includes a rearwardly extending portion 32, corresponding to the lower side edges of the hood, a vertical portion 34 extending upward from the back end of the rearwardly extending portion 32, and a top portion 36 extending horizontally from the vertical portion 34, and corresponding to the top rear edge of the hood.
  • Presently available hoods may also include a plenum 38, for reinforcing an air intake located on the top of the hood, and leading to the engine, as depicted in Figure 5.
  • the present invention provides a vehicle body component such as a truck hood having a metal skin reinforced by a plurality of polymer and metal reinforcements secured to the interior of the skin.
  • the truck hood including:
  • a metal hood skin including at least an upper portion and a sidewall portion
  • a frame supporting at least a portion of the metal hood skin including a polymer reinforcement secured to an interior side of the hood skin, the polymer reinforcement including a front hood stiffener member positioned at a front end portion of the metal hood skin, a rear hood stiffener member positioned at a rear end portion of the metal hood skin and hood corner longitudinal members connecting the front hood stiffener member to the rear hood stiffener member and positioned along at a transition between the upper portion and sidewall portion of the metal hood skin.
  • the metal skin may be formed of two skin portions secured to each other, a first hood skin portion including the upper and sidewall portions of the metal hood skin and a second hood skin portion including a pair offenders.
  • the taick hood further includes an arch extruded reinforcement (also referred to as arch extrusion), preferably being aluminum, reinforcing the connection between the first hood skin portion including the upper and sidewall portions of the metal hood skin and second hood skin portion including a pair offenders.
  • the arch extaided reinforcement may have a geometry corresponding to the wheel arch of a wheel well.
  • the truck hood may further include front frame and rear frame extruded members, preferably being aluminum, positioned to support at least the sidewall portion of the metal hood skin.
  • the front and rear frame extruded member form a triangular truss staicture with a base provided by the arch extruded reinforcement and with an apex connected to the hood corner longitudinal members.
  • the truck hood may further include a node casting, preferably composed of aluminum, at the apex of the front and rear extruded members including a spring attachment member; a rear hood support casting connected to the rear extaided member; and a pivot member casting connected to the arch extaided member and positioned at the front end portion of the metal hood skin.
  • a method of forming a truck hood in which a polymer reinforcement supports at least a portion of the taick hood skin.
  • the method including:
  • Figure 1 is a perspective view of the reinforcements presently utilized with fiberglass reinforced polymer truck hoods, as known in the prior art.
  • Figure 2 is a perspective view of a front reinforcement presently used with fiberglass reinforced polymer truck hoods, as known in the prior art.
  • Figure 3 is a perspective view of a headlight reinforcement presently used with fiberglass reinforced polymer truck hoods, as known in the prior art.
  • Figure 4 is a perspective view of a side reinforcement presently used with fiberglass reinforced polymer truck hoods, as known in the prior art.
  • Figure 5 is a perspective view of a plenum presently used with fiberglass reinforced polymer truck hoods, as known in the prior art.
  • Figure 6 is a perspective view of one preferred embodiment of a truck hood in accordance with the present invention, in which the lower hood panel of the truck hood is included so that it may be made in the same color as the remainder of the truck hood.
  • Figure 7 is a perspective view of a lower hood panel, in accordance with the present invention.
  • Figure 8 is a perspective view of another preferred embodiment of a truck hood in accordance with the present invention, in which the lower hood panel is omitted so that it may be provided as part of the grille.
  • Figure 9 is an exploded view of a truck hood in accordance with the present invention.
  • Figure 10 is a perspective view of one embodiment of a truck hood reinforcing structure in accordance with the present invention.
  • Figure 11 is a perspective view of one embodiment of the front hood stiffener member and rear hood stiffener member of the polymer reinforcement and one embodiment of a pivot cast member, in accordance with the present invention.
  • Figure 12 is an interior side view of the sidewall portion of one embodiment of a taick hood in accordance with the present invention.
  • Figures 13 a- 13b are perspective views of the connection between the first portion of the hood skin and the second portion of the hood skin, in which the second portion of the hood skin includes fenders.
  • Figure 13 c is a section view of a truck hood and fender structure in accordance with the present invention.
  • FIG. 6 depicts one embodiment of a truck hood 40 in accordance with the present invention.
  • the truck hood 40 is to be employed in long haul trucks, such as Class 8 truck applications.
  • the truck hood 40 includes a hood skin having a top or upper surface 41, a right sidewall 42 joined to the upper surface 41, and a left sidewall 43 joined to the other side of the upper surface 41.
  • the upper surface 41 and sidewalls 42, 43 of the metal hood skin may be made from any metal having suitable strength and weight, with preferred metals including aluminum, such as Aluminum Association 3XXX, 5XXX or 6XXX series aluminum alloy sheet, preferably having a thickness of about 1.5 mm to about 2.5 mm.
  • the metal skin is preferably formed into a desired shape by any sheet metal forming process, such as stamping.
  • Fender skin structures 44, 45 may be formed integrated into the sidewall portions 42, 43 of the hood skin to provide a singular structure or may be detachably connected to the sidewall portions 42, 43 of the hood skin. Each of the fender skin staictures 44, 45 may include a headlight opening 46, 47 therein.
  • the sidewall portions 42, 43 and fender structures 44, 45 may be joined by presently available methods such as spot welding, other forms of welding, or other forms of mechanical fastening, such as nut and bolt arrangements and riveting.
  • a front panel 52 is also included so that it may be made in the same color as the remainder of the truck hood 40.
  • One embodiment of a front panel 52 is depicted in Figure 7.
  • the front panel 52 may be connected between the opposing lower front corners of the fender skin structures 44, 45 by mechanical attachment, including nut and bolt arrangements, rivets and combinations thereof.
  • Figure 8 depicts another embodiment of a hood structure 40 provided in accordance with the present invention, in which the front panel is omitted so that it may be provided as part of the grille, and may have the same finish or chrome plating as the grille.
  • FIG. 9 depicts an exploded view of one embodiment of a hood structure 40, in accordance with the present invention.
  • the hood structure 40 includes a metal hood skin 53 , a frame 54 supporting at least a portion of the metal hood skin 53, and a reinforced fender assembly 55.
  • Figure 10 depicts one embodiment of a frame 54 for supporting at least a portion of the metal hood skin 53.
  • the frame 54 includes a polymer reinforcement secured to the interior side of the hood skin 53, in which the polymer reinforcement includes a front hood stiffener member 56 positioned corresponding to a front end portion of the metal hood skin 53, a rear hood stiffener member 57 positioned corresponding to a rear end portion of the metal hood skin 53 and hood corner longitudinal members 58 connecting the front hood stiffener member 56 to the rear hood stiffener member 57 and positioned corresponding to the transition between the upper surface 41 and sidewall portions 42, 43 of the metal hood skin 53.
  • the front hood stiffener member 56 and the rear hood stiffener member 57 have a generally U-shaped geometry corresponding to the interior surface of the metal hood skin 53.
  • one preferred polymer reinforcement front hood stiffener member 56 includes a top portion 59 having a right side portion 60 and left side portion 61 depending downward therefrom.
  • the top portion 59, right side portion 60, and left side portion 61 define an opening 62 therein, structured to receive a grille.
  • the right side portion 60 and left side portion 61 each includes a headlight support portion 62, 63, preferably in a lower portion of the right side portion 60 and left side portion 61.
  • One preferred polymer reinforcement rear hood stiffener member 57 includes top portion 64 having a right side portion 65 and left side portion 66 depending downward therefrom.
  • the right side portion 65 and left side portion 66 of the rear hood stiffener member 57 have an increased thickness corresponding to the portions of the metal hood skin 53 requiring additional reinforcement.
  • the rear hood stiffener member 57 may further include plurality of vents 67 defined in the center of the top portion 64.
  • the hood corner longitudinal members 58 connecting the front hood stiffener member 56 to the rear hood stiffener member 57 are positioned corresponding to the transition between the upper surface 41 and sidewall portions 42, 43 of the metal hood skin 53.
  • the hood corner longitudinal member 58 is configured to provide the base of a triangle formed between the hood longitudinal member 58, the upper surface 41 of the metal skin 53, and the sidewall 42, 43 of the metal skin in a manner that reinforces the transition between the upper surface 41 and the sidewalls 53.
  • the front hood stiffener member 56 and the rear hood stiffener member have a thickness on the order of about 3.0 mm.
  • the polymer reinforcements may be made from any suitable polymer, with suggested materials including thermoplastic and thermoset sheet, thermoplastic and thermoset molding pellet, as well as sheet molding compounds.
  • the polymer includes nylon containing polymers, one preferred polymer including greater than 50.0 weight % polyhexamethylene adipamide (nylon 66), greater than 30.0 weight % inert filler, less than 3.0 weight % carbon black, less than 3.0 weight % titanium dioxide, and less than 1.0 weight % of colorants, lubricants and stabilizers.
  • Another preferred polymer includes than 60.0 weight % polyhexamethylene adipamide (nylon 66), greater than 30.0 weight % inert filler, less than 1.0 weight % carbon black, and less than 15.0 weight % of short glass fibers.
  • Another preferred polymer is Minlon IM available from Dupont Inc.
  • the polymer reinforcements may be formed from processes such as molding and vacuum thermoforming, with vacuum thermoforming being most preferred for low volume production.
  • the polymer reinforcements may be attached to the metal skin by either mechanical fasteners or by adhesives.
  • the polymer reinforcements occupy about 20% to about 30% of the interior surface area of the truck hood 40, and comprise about 25% to about 35% of the total weight of the truck hood 40.
  • the frame 54 may further include an arch extaided reinforcement 68, preferably of aluminum, reinforcing a connection between the metal hood skin 53 and the reinforced fender structure 55, wherein the arch extruded reinforcement 68 corresponds to the wheel arch of a wheel well.
  • the arch extaided reinforcement 68 is formed of a 6XXX series aluminum, most preferably being an extrusion of Aluminum Association 6061-T6.
  • the term "extrusion" is meant to define that the member is made using an extrusion process, in which the extrusion has a substantially uniform cross section dictated by the extrusion die.
  • the arch extruded reinforcement 68 has a thickness on the order of about 2.0 mm.
  • the frame 54 further includes front frame and rear frame extruded members 69, 70, preferably of aluminum, positioned to support at least the sidewall portion 42, 43 of the metal hood skin 53.
  • the front and rear frame extruded member 69, 70 form a triangular structure with a base provided by the arch extruded reinforcement 68 and with an apex 71 connected to the hood corner longitudinal members 58
  • the front frame and rear frame extruded members 69, 70 are formed of a 6XXX or 5XXX series aluminum, most preferably being an extrusion of Aluminum Association 6061- T6.
  • the arch extaided reinforcement 68 has a thickness on the order of about 2.0 mm.
  • Figure 12 is an interior side-view of the sidewall 42 portion of one embodiment of the inventive truck hood and depicts the portion of the frame 54 that supports at least the sidewalls 42 of the metal skin 53.
  • the portion of the frame 54 supporting the sidewalls 42 includes at least the front and rear frame extruded member 69, 70.
  • the taick hood 40 further includes a node 71 at the apex of the front and rear extruded members 69, 70 including a spring attachment member.
  • the node 71 is formed from a metal sheet, preferably including a 5XXX or 6XXX series alloy, such as Aluminum Association 6061 treated to T4 temper.
  • the node 71 is a casting of Aluminum Association A356-T6.
  • the truck hood 40 further includes a rear hood support casting 72 connected to the rear extruded member 70.
  • the rear hood support casting 72 is configured to act a support for the truck hood 40 when in the closed position.
  • the rear hood support casting 72 is cast from a 3XX series alloy, such as Aluminum Association A356-T6.
  • the truck hood 40 further includes a pivot member casting 73 connected to the arch extaided reinforcement 68 and positioned at the front end portion of the metal hood skin 53.
  • the pivot casting 73 may be of any geometry that would support the operation weight of the hood 40 when open and closed.
  • the pivot member casting 73 is cast from a 3XX series alloy, such as Aluminum Association A356-T6.
  • the taick hood 40 may include a cross brace 74 positioned between the pivot member castings 73, wherein the cross brace 74 is preferably an extaided aluminum member, as depicted in Figure 9.
  • the cross brace 74 is extruded of an Aluminum Association 6XXX alloy, most preferably being Aluminum Association 6061-T6.
  • Figures 13 A- 13 C depict one embodiment of a reinforced fender structure 55, in which the connection between the metal hood skin 53 and the fender structure 55 is strengthened by the arch extruded reinforcement 68.
  • the reinforced fender structure 55 includes fender skin structures 44, 45, a weatherstrip component 75 and a reinforcing fender mat 76.
  • the fender skin structures 44, 45 include a stamped metal skin and may be made from any metal having suitable strength and weight, with preferred metals including 3XXX, 5XXX or 6XXX series aluminum alloy sheet having a thickness of about 1.5 mm to about 2.5 mm, preferably being 2.0 mm.
  • the metal fender skin structures 44, 45 are preferably formed into a desired shape by any sheet metal forming process such as stamping.
  • the weatherstrip component 75 is preferably a polymer material, such as Polyvinyl chloride (PVC).
  • the reinforcing fender mat 76 may be formed, preferably molded, from any suitable polymer, with suggested materials including thermoplastic and thermoset sheet, thermoplastic and thermoset molding pellet, as well as sheet molding compounds.
  • the polymer of the reinforced fender mat 76 includes nylon containing polymers, one preferred polymer including greater than 50.0 weight % polyhexamethylene adipamide (nylon 66), greater than 30.0 weight % inert filler, less than 3.0 weight % carbon black, less than 3.0 weight % titanium dioxide, and less than 1.0 weight % of colorants, lubricants and stabilizers.
  • Another preferred polymer includes than 60.0 weight % polyhexamethylene adipamide (nylon 66), greater than 30.0 weight % inert filler, less than 1.0 weight % carbon black, and less than 15.0 weight % of short glass fibers.
  • Another preferred polymer is MinionTM available from Dupont Inc.
  • the polymer reinforcing fender mat 76 may be formed from processes such as molding and vacuum thermoforming and may have a thickness on the order of 5.0 mm.
  • the reinforced fender structure 55 is connected to the sidewalls 42, 43 of the truck hood 40 by engagement between the polymer reinforcing fender mat 76 and the sidewall portions 42, 43.
  • the engagement between the polymer reinforcing fender mat 76 and the sidewall portions 42,43 may be provided by mechanical attachment, including nut and bolt arrangements, rivots and combinations thereof; by welding operations, such as spot welding; or adhesively.
  • the engagement of the fender skin structure 44 and the polymer reinforcing mat 76 is strengthened by the arch extruded reinforcement 68, wherein the polymer reinforcing mat 76 is mechanically attached to the arch extaided reinforcement 68 through the sidewall portion 42, 43 of the hood skin 53.
  • the polymer weatherstrip 75 provides sealing engagement between first hood skin portion including the upper and sidewall portions 41, 42, 43 and the second hood skin portion including the fender skin structure 44, 45.
  • the number of parts included in the truck hood 40 of the present invention has been reduced from 21 to 10, providing for a reduction in weight from about 167 lbs. to about 90 lbs. Part of this weight savings is derived from the decreased need to reinforce an aluminum skin as compared to a polymer skin. In one embodiment, it is only necessary for the polymer reinforcements to occupy about 20% to about 30% of the interior surface of the truck hood 40, and to comprise about 25% to about 35% of the total weight of the truck hood 40.
  • the present invention provides a truck hood having a better strength to weight ratio than presently available taick hood structures.
  • the present invention further provides a truck hood component that facilitates access to those portions of the vehicle that it covers by being easier to raise and lower due to its light weight.
  • the present invention also provides a vehicle body component made from fewer subcomponents.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Body Structure For Vehicles (AREA)
  • Superstructure Of Vehicle (AREA)

Abstract

La présente invention concerne un capot de camion (40) comprenant un revêtement de capot métallique (53) comprenant au moins une partie supérieure et une partie latérale ; et un cadre (54) supportant au moins une partie du revêtement de capot métallique comprenant des renforts de polymère et d'aluminium. Les renforts de polymère comprennent un élément raidisseur de capot avant (56) positionné au niveau d'une partie d'extrémité avant du revêtement de capot métallique, un élément raidisseur de capot arrière (57) positionné au niveau d'une partie d'extrémité arrière du revêtement de capot métallique et des éléments longitudinaux de coin de capot (58) reliant l'élément raidisseur de capot avant à l'élément raidisseur de capot arrière. Les renforts d'aluminium comprennent des éléments extrudés de cadre avant et arrière (69, 70) positionnés le long des parois latérales (42, 43) du revêtement de capot métallique et un renfort extrudé de passage (68) positionné au niveau du passage de la roue. Selon un aspect de l'invention, le capot de camion comprend en outre une paire d'ailes (59) formées d'un revêtement métallique qui peut être renforcé au moyen d'un matériau d'aile de polymère (76).
PCT/US2007/076765 2006-08-28 2007-08-24 Capot de camion en matériau hybride léger WO2008027805A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US11/467,627 2006-08-28
US11/467,627 US7815249B2 (en) 2006-08-28 2006-08-28 Lightweight hybrid material truck hood

Publications (1)

Publication Number Publication Date
WO2008027805A1 true WO2008027805A1 (fr) 2008-03-06

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US (2) US7815249B2 (fr)
WO (1) WO2008027805A1 (fr)

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US8128159B2 (en) 2006-08-28 2012-03-06 Alcoa Inc. Lightweight hybrid material truck hoods
CN110001789A (zh) * 2019-04-30 2019-07-12 北京长城华冠汽车科技股份有限公司 机舱盖组件和具有它的车辆
KR20210144286A (ko) * 2020-05-22 2021-11-30 이강주 버스용 사이드 패널
KR102446613B1 (ko) * 2020-05-22 2022-09-22 이강주 버스용 사이드 패널

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US20110001338A1 (en) 2011-01-06
US7815249B2 (en) 2010-10-19
US20080048471A1 (en) 2008-02-28

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